York EX Series Installation, Operation & Maintenance Instructions Manual Download

Page: 5 / 176

JOHNSON CONTROLS

FORM 155.32-ICOM1.EN.GB

ISSUE DATE: 10/13/2017

TABLE OF CONTENTS

SECTION 1 – GENERAL CHILLER-HEATER INFORMATION AND SAFETY ...................................................... 11

Introduction ..................................................................................................................................................... 11

About this Manual ........................................................................................................................................... 11

Warranty ......................................................................................................................................................... 11

Quality Assurance .........................................................................................................................................12

High Temperature and Pressure Cleaning ....................................................................................................12

Safety Labels ..................................................................................................................................................13

SECTION 2 – PRODUCT DESCRIPTION ..............................................................................................................15

Chiller-Heater Components ............................................................................................................................15

Control Panel ..................................................................................................................................................15

How It Works (Direct Fired Units) ...................................................................................................................16

Evaporator ......................................................................................................................................................17

Absorber .........................................................................................................................................................17

Two-step Evaporator – Absorber ....................................................................................................................17

Plate Type Heat Exchangers ..........................................................................................................................18

Parallel Flow ...................................................................................................................................................18

High Temperature Generator (HTG) ...............................................................................................................18

Low Temperature Generator (LTG) ................................................................................................................18

Condenser ......................................................................................................................................................19

Crystallization .................................................................................................................................................19

Why Does Crystallization Occur? ...................................................................................................................19

SECTION 3 – HANDLING, STORAGE, INSTALLATION AND REASSEMBLY .....................................................21

Inspection .......................................................................................................................................................22

Inspection Window .........................................................................................................................................22

Installation Guidelines ....................................................................................................................................22

Structural Support and Installation .................................................................................................................22

Indoor and Outdoor Installation ......................................................................................................................23

Precautions for Use .......................................................................................................................................23

Leak testing ....................................................................................................................................................24

Electrical Shock Cautions ...............................................................................................................................24

Use of Gas .....................................................................................................................................................25

Vibration and Isolation Details ........................................................................................................................25

Hot Insulation/Cold Insulation Procedure .......................................................................................................29

SECTION 4 - TECHNICAL DATA ...........................................................................................................................31

Upper Communication Specification ..............................................................................................................68

Upper Communication System Configuration

.......................................................................................68

Scope of Delivery ..................................................................................................................................69

Connection Port for Ethernet Communication .......................................................................................69

Communication Specification

................................................................................................................70

Communication Data .............................................................................................................................70

User-Created ........................................................................................................................................72

4-Wire Type Cable Diagrams ................................................................................................................74

Summary of Contents for EX Series

Page 1: ...EX EXW 50 Hz 120 1600 TON 422 5626 KW DOUBLE EFFECT DIRECT FIRED ABSORPTION CHILLER HEATER INSTALLATION OPERATION MAINTENANCE SUPERSEDES 155 32 ICOM1 EN GB 217 Form 155 32 ICOM1 EN GB 1017 Issue Date...

Page 2: ...els this document and any referenced materials This in dividual shall also be familiar with and comply with all applicable industry and governmental standards and regulations pertaining to the task in...

Page 3: ...to the man ual or product owner It is the responsibility of rigging lifting and operating service personnel to verify the applicability of these documents to the equipment If there is any question reg...

Page 4: ...ion Chiller HEATING CAPACITY N Standard H HTG One Size Larger S JE LL WASTE HOT WATER HEAT RECOVERY None No heat recovery J Heat recovery Standard JE Heat recovery Enlarged type LOW TEMP CHW L 1 0 C C...

Page 5: ...w Temperature Generator LTG 18 Condenser 19 Crystallization 19 Why Does Crystallization Occur 19 SECTION 3 HANDLING STORAGE INSTALLATION AND REASSEMBLY 21 Inspection 22 Inspection Window 22 Installati...

Page 6: ...Switch 116 Select Language 116 Single Loop Controller 117 Run Mode 118 Ready Mode 118 Alarm Mode 119 Alarm Codes 120 Air Damper Control 121 Hot Water Control Valve 122 AUTO MANUAL Mode RHW only 123 Op...

Page 7: ...Purge Manual Start and Stop 148 Lifespan for Various Parts 148 Water Quality Control 150 Chemical Water Treatment 151 Replacement of Water 151 Treatment For Long Stoppage Of The Absorption Chiller He...

Page 8: ...with User Created Cable 74 FIGURE 24 4 Wire 1 1 Connection With User Created Cable 74 FIGURE 25 4 Wire N 1 Connection With User Created Cable 75 FIGURE 26 Sample Sound Testing 76 FIGURE 27 Cooling St...

Page 9: ...Chiller Heater Flow Diagram Simultaneous Heating and Residential Hot Water 139 FIGURE 58 Process and Instrumentation Diagram Cooling Only 140 FIGURE 59 YHAU CGN H Direct Fired Chiller Heater Flow Diag...

Page 10: ...Write Command 71 TABLE 25 Scope of Delivery of Upper Communication System 72 TABLE 26 Cable Diagram RS 422 RS485 73 TABLE 27 Communication Specifications 75 TABLE 28 Rotary Pump Rotation 77 TABLE 29 L...

Page 11: ...ure to follow the procedures and instruc tions detailed in this manual WARRANTY Johnson Controls warrants YHAU CG H chiller heaters in accordance with the Limited Warranty En gineered Systems Equipmen...

Page 12: ...rect fired lithium bromide absorption water chiller heater GB 18361 2001 Safety requirements of lithium bromide absorption water chiller heater The unit must be grounded No installation or main tenanc...

Page 13: ...machine may start auto matically without prior warning Warning Hot surface Warning Safety relief valve may dis charge gas or liquid without prior warning Warning Risk of electric shock General attenti...

Page 14: ...JOHNSON CONTROLS 14 FORM 155 32 ICOM1 EN GB ISSUE DATE 10 13 2017 SECTION 1 GENERAL CHILLER HEATER INFORMATION AND SAFETY THIS PAGE INTENTIONALLY LEFT BLANK...

Page 15: ...e efficiency pumps to circulate the refrigerant and solution in the cycle purge unit to remove non condensable gas from the machine CONTROL PANEL The absorption chiller heater comes with a factory mou...

Page 16: ...IULJHUDQW 3XPS 6ROXWLRQ LUFXODWLRQ 3XPS 6ROXWLRQ 6SUD 3XPS RZ 7HPS HQHUDWRU UDLQ HDW FKDQJHU RQGHQVHU RZ 7HPS HQHUDWRU KLOOHG DWHU RROLQJ DWHU 5HIULJHUDQW LOXWHG 6ROXWLRQ RQFHQWUDWHG 6ROXWLRQ D 9 KDXV...

Page 17: ...of the solution pump The liquid is then pumped to the generators The following section describes the unique 2 step evaporator absorber design of the YHAU CG direct fired absorption chiller heater TWO...

Page 18: ...solution to solution plate type heat exchangers optimize efficiency by enabling effec tive heat transfer between the diluted weak and the concentrated LiBr solutions HIGH TEMPERATURE GENERATOR HTG YH...

Page 19: ...igh enough in most load conditions no crystal lization will occur as long as the higher solution tem peratures are maintained Special measures do have to be taken before the unit is shut down so that...

Page 20: ...JOHNSON CONTROLS 20 FORM 155 32 ICOM1 EN GB ISSUE DATE 10 13 2017 SECTION 2 PRODUCT DESCRIPTION THIS PAGE INTENTIONALLY LEFT BLANK...

Page 21: ...gging equipment available and site needs Therefore a professional rig ger must determine the rigging and lifting method to be used and it is beyond the scope of this manual to specify rigging and lift...

Page 22: ...er and may result in a seri ous accident The smokestack and cooling tower must be placed at least 5 meters apart Wherever possible the smokestack should be positioned downwind of the cooling tower wit...

Page 23: ...torage area as much as possible to keep the humidity low Avoid storing the unit in an area where the humidity is 95 RH or higher and the tem perature is 40 C 104 F or higher For more informa tion abou...

Page 24: ...he fuel gas line If not it may cause electric shock and burn If the cables of the solution pump refrigerant pump burner fan and or vacuum pump are disconnected for service and maintenance work be sure...

Page 25: ...s If black and white smoke is produced stop the ma chine and contact your local Johnson Controls Ser vice Office for assistance Do not block the outer cover suction port or exhaust port This can cause...

Page 26: ...2017 SECTION 3 HANDLING STORAGE INSTALLATION AND REASSEMBLY LD20186 Base Sole Plate Rubber Vibration Isolator Foundation Bolt Washer Nut Washer Nut Foundation Bolt Rubber Vibration Isolator Sole Plate...

Page 27: ...documents for detailed nozzle locations for each specific unit Figure 5 YHAU CGN H 120 300EX H S AND 360EX H S 1600EXW3 H S NOZZLE LOCATIONS LD20182 Gas Fired 180 300EXS HNG B Side A Side 1 2 3 4 5 6...

Page 28: ...Elec Op Butterfly Valve Pressure Gauge Blower Air Pressure Switch Scope of Supply Electric Operated Butterfly Valve Pilot Burner Main Burner Main Safety Shut Off Valve Electric Operated Butterfly Val...

Page 29: ...OT INSULATION POINT REQUIRING COLD INSULATION POINT THAT MUST NOT BE HEAT INSULATED High Temperature Generator Evaporator Shell Sight Glass Flue Evaporator Water Chamber Case Valve Manipulator Heat Ex...

Page 30: ...ISSUE DATE 10 13 2017 SECTION 3 HANDLING STORAGE INSTALLATION AND REASSEMBLY LD20178 Figure 8 INTERIOR OF CONTROL PANEL MM Figure 9 EXTERIOR OF CONTROL PANEL MM X HU DQ URXQG 7HUPLQDO RRU 6WRSSHU UDZ...

Page 31: ...ONAL RANGE PARAMETER ALLOWABLE RANGES Chilled Water In 7 25 C Chilled Water Out 4 16 C Cooling Water In 20 37 C Cooling Water Out 25 42 C Natural Gas Inlet Pressure 120 300 RT 2 250 kPa g 360 1600 RT...

Page 32: ...0 2 1400EXW3S 44 4 49 8 79 8 47 8 53 2 84 7 1500EXW3S 43 1 55 2 87 1 44 3 56 8 90 3 1600EXW3S 44 4 56 7 90 4 45 6 58 3 93 7 Table 6 HIGH EFFICIENCY YHAU WEIGHTS CGN WEIGHTS CGH MAXIMUM SHIPPING TON OP...

Page 33: ...0 1200EXW3 H S 8 629 8 300 3 200 3 300 7 000 67 0 43 0 1 68 3 28 1300EXW3 H S 9 970 8 800 3 300 3 300 7 500 77 0 46 0 1 80 3 40 1400EXW3 H S 9 970 9 300 3 300 3 300 8 000 81 0 48 0 1 89 3 55 1500EXW3...

Page 34: ...60 0 2 2 6 1 23 0 AC400V 3Ph 50Hz 13 5 63 0 5 8 24 0 560 EX H S AC380V 3Ph 50Hz 40 A 63 A 5 5 14 2 60 0 2 2 6 1 23 0 AC400V 3Ph 50Hz 13 5 63 0 5 8 24 0 600 EX H S AC380V 3Ph 50Hz 40 A 63 A 5 5 14 2 60...

Page 35: ...8 21 2 17 0 6 1 65 4 4 1 8 9 0 7 9 84 0 21 5 17 2 560 EX H S 0 4 1 6 4 2 0 75 1 8 9 0 4 8 1 79 8 21 2 17 0 6 1 65 4 4 1 8 9 0 7 9 84 0 21 5 17 2 600 EX H S 0 4 1 6 4 2 0 75 1 8 9 0 4 8 1 79 8 21 2 17...

Page 36: ...0 5 8 24 0 800 EX H S AC380V 3Ph 50Hz 50 A 63 A 5 5 14 2 60 0 2 2 6 5 20 3 AC400V 3Ph 50Hz 13 5 63 0 6 2 21 0 900 EX H S AC380V 3Ph 50Hz 50 A 63 A 5 5 14 2 60 0 2 2 6 5 20 3 AC400V 3Ph 50Hz 13 5 63 0...

Page 37: ...3 3 18 6 800 EX H S 0 4 1 6 4 2 0 75 1 8 9 0 7 5 14 7 144 0 25 8 20 7 6 1 65 4 4 1 8 9 0 14 2 147 0 26 2 20 9 900 EX H S 1 3 3 9 11 9 0 75 1 8 9 0 7 5 14 7 144 0 27 4 21 9 6 3 8 12 8 1 8 9 0 14 2 147...

Page 38: ...4 3 96 2 00 300EXH 3 71 2 99 4 48 2 29 360EXH 4 54 3 51 5 27 2 73 400EXH 5 09 3 93 5 89 3 03 450EXH 5 55 4 01 6 01 3 19 500EXH 6 14 3 96 5 95 4 00 560EXH 7 03 4 70 7 06 4 14 600EXH 7 55 4 88 7 31 4 76...

Page 39: ...XH 300EXH 360EXH 400EXH 450EXH 13 0 7 81 11 7 8 63 500EXH 13 8 9 05 13 6 8 95 560EXH 13 6 9 97 15 0 9 23 600EXH 14 9 10 30 15 5 10 7 700EXH 15 7 10 9 16 3 11 2 800EXH 16 7 10 9 16 4 12 5 900EXWH 17 2...

Page 40: ...2 53 3 79 1 91 300EXS 3 57 2 88 4 31 2 20 360EXS 4 34 3 35 5 03 2 61 400EXS 4 88 3 77 5 65 2 91 450EXS 4 99 3 61 5 41 2 87 500EXS 5 65 3 64 5 47 3 68 560EXS 6 49 4 34 6 51 3 82 600EXS 7 14 4 61 6 92 4...

Page 41: ...XS 300EXS 360EXS 400EXS 450EXS 12 3 7 43 11 1 8 21 500EXS 13 2 8 65 13 0 8 55 560EXS 13 0 9 55 14 3 8 85 600EXS 14 3 9 91 14 9 10 29 700EXS 15 1 10 48 15 7 10 8 800EXS 16 2 10 6 15 9 12 1 900EXWS 16 7...

Page 42: ...2 1 5 1 1 2 9 5 6 1 0 2 0 2 7 450EXH 4 9 2 3 2 8 9 8 4 7 1 6 1 1 2 3 4 7 1 0 2 0 2 7 500EXH 5 4 2 3 2 8 10 0 5 2 1 6 1 1 2 5 4 8 1 4 2 0 3 4 560EXH 5 9 2 3 2 8 11 1 5 7 1 6 1 1 2 7 5 1 1 4 2 0 3 5 600...

Page 43: ...EXH 5 9 2 3 2 8 11 1 5 7 1 6 1 1 2 7 5 1 1 4 2 0 3 9 600EXH 6 4 2 5 2 8 12 2 6 2 1 6 1 1 2 9 5 2 1 4 2 0 4 5 700EXH 7 2 2 5 2 8 14 8 7 0 1 6 1 1 3 2 5 9 1 4 2 0 4 5 800EXH 7 9 2 5 2 8 17 6 7 7 1 6 1 1...

Page 44: ...6 2 1 5 1 1 1 2 5 6 1 0 2 0 2 7 450EXS 4 9 2 3 2 8 9 8 4 7 1 6 1 1 1 2 4 7 1 0 2 0 2 7 500EXS 5 4 2 3 2 8 10 0 5 2 1 6 1 1 1 2 4 8 1 4 2 0 3 4 560EXS 5 9 2 3 2 8 11 1 5 7 1 6 1 1 1 2 5 1 1 4 2 0 3 5 6...

Page 45: ...0EXS 6 4 2 5 2 8 12 2 6 2 1 6 1 1 1 2 5 2 1 4 2 0 4 5 600EXS 7 2 2 5 2 8 14 8 7 0 1 6 1 1 1 4 5 9 1 4 2 0 4 5 700EXS 7 9 2 5 2 8 17 6 7 7 1 6 1 1 1 6 6 6 1 7 2 8 7 0 800EXS 7 3 2 6 2 8 20 6 6 7 1 8 1...

Page 46: ...JOHNSON CONTROLS 46 FORM 155 32 ICOM1 EN GB ISSUE DATE 10 13 2017 SECTION 4 TECHNICAL DATA Figure 10 POWER WIRING LD20248 Solution Circulation Pump Solution Spray Pump Refrigerant Pump Power Source...

Page 47: ...JOHNSON CONTROLS 47 SECTION 4 TECHNICAL DATA FORM 155 32 ICOM1 EN GB ISSUE DATE 10 13 2017 4 FIGURE 10 POWER WIRING CONT LD20248a Burner Fan Purge Pump...

Page 48: ...55 32 ICOM1 EN GB ISSUE DATE 10 13 2017 SECTION 4 TECHNICAL DATA Figure 11 POWER SUPPLY WIRING LD20248 Surge Absorber Solution Circulation Pump Solution Spray Pump Refrigerant Pump Output One Second P...

Page 49: ...SECTION 4 TECHNICAL DATA FORM 155 32 ICOM1 EN GB ISSUE DATE 10 13 2017 4 FIGURE 11 POWER SUPPLY WIRING CONT D LD20250 Purge Pump Protection Relay HT GEN Solution Level Relay HT GEN High Pressure Rela...

Page 50: ...2017 SECTION 4 TECHNICAL DATA FIGURE 11 POWER SUPPLY WIRING CONT D LD20251 Air Pressure Switch Full Close Confirm Full Close Confirm Full Open Confirm Flame Detector Ignition Transformer Pilot Valve...

Page 51: ...JOHNSON CONTROLS 51 SECTION 4 TECHNICAL DATA FORM 155 32 ICOM1 EN GB ISSUE DATE 10 13 2017 4 FIGURE 11 POWER SUPPLY WIRING CONT D LD20252 Control Motor for Air Control Motor for Gas Open Close...

Page 52: ...ration Signal DC24 V Pulse Remote Operation Stop Signal Pulse Remote Operation Stop Signal Level Burner Fan Operation Signal Oil Pump Operation Signal Oil Model Purge Pump HT GEN Solution Level Combus...

Page 53: ...liary Input Auxiliary Input Burner Fan Auxiliary Input SDC1 Abnormal Option Inverter Abnormal Option Chilled Hot Water Suspension Cut Out Relay Ignition Condition Cooling Water Suspension Cut Out Rela...

Page 54: ...5 32 ICOM1 EN GB ISSUE DATE 10 13 2017 SECTION 4 TECHNICAL DATA FIGURE 12 PLC INPUT WIRING CONT D LD20255 RP Operation SP1 Operation SP2 Operation Instantaneous Power Failure Detection Nor mally close...

Page 55: ...ON 4 TECHNICAL DATA FORM 155 32 ICOM1 EN GB ISSUE DATE 10 13 2017 4 LD20255a Gas Pressure Switch Refrigerant Liquid Level Switch Gas High Pressure Switch Gas Low Pressure Switch Flame Failure FIGURE 1...

Page 56: ...OM1 EN GB ISSUE DATE 10 13 2017 SECTION 4 TECHNICAL DATA Figure 13 PLC OUTPUT WIRING LD20256 Contact Output Local Standard Loop Exhaust Fan Operation Cooling Water Pump Operation Chilled Hot Water Pum...

Page 57: ...ION 4 TECHNICAL DATA FORM 155 32 ICOM1 EN GB ISSUE DATE 10 13 2017 4 LD20256a Failure Alarm Combustion Dilution Cooling Heating Remote Local Cooling Water Temperature Abnormal Operation COM FIGURE 13...

Page 58: ...DATE 10 13 2017 SECTION 4 TECHNICAL DATA FIGURE 13 PLC OUTPUT WIRING CONT D LD20257 Contact Output Combustion Command Local Refrigerant Blow Solenoid Valve Automatic Purge with Vacuum Pump Purge Solen...

Page 59: ...JOHNSON CONTROLS 59 SECTION 4 TECHNICAL DATA FORM 155 32 ICOM1 EN GB ISSUE DATE 10 13 2017 4 LD20258 Buzzer External Signal Output FIGURE 13 PLC OUTPUT WIRING CONT D...

Page 60: ...M 155 32 ICOM1 EN GB ISSUE DATE 10 13 2017 SECTION 4 TECHNICAL DATA Figure 14 PLC ANALOG INPUT WIRING LD20259 Local T C 1 Cooling Water Inlet T C 3 Absorber RTD 1 Chilled Hot Water Inlet RTD 2 Chilled...

Page 61: ...61 SECTION 4 TECHNICAL DATA FORM 155 32 ICOM1 EN GB ISSUE DATE 10 13 2017 4 FIGURE 14 PLC ANALOG INPUT WIRING CONT D LD20260 T C 2 Cooling Water Outlet T C 4 HT GEN Temperature T C 6 Exhaust Gas RTD...

Page 62: ...TECHNICAL DATA Figure 15 DISPLAY ANALOG INPUT WIRING LD20261 Touch Panel Current Output Variable Cooling Water Flow Signal Current Output SDC1 PV SHT 3 Current Output Solution Circulation Pump Frequen...

Page 63: ...OM1 EN GB ISSUE DATE 10 13 2017 4 FIGURE 15 DISPLAY ANALOG INPUT WIRING CONT D LD20262 Current Input HT GEN Pressure Sensor Current Input Remote Chilled Hot Water Outlet Temperature Setting Signal Cur...

Page 64: ...7 SECTION 4 TECHNICAL DATA LD20570 Figure 16 EXTERNAL CONNECTION TERMINAL DETAILS AUXILIARY EQUIPMENT PANEL ABSORPTION CHILLER HEATER CONTROL PANEL FAILURE SIGNAL ALARM SIGNAL FAILURE SIGNAL In case o...

Page 65: ...IGNAL PERMIT RESISTANCE LOAD 500 COOLING WATER FLOW SIGNAL 4 mA 50 FLOW 20mA 100 FLOW EXTERNAL OUTPUT TERMINAL ABSORPTION CHILLER HEATER CONTROL PANEL DIGITAL SIGNAL RATED VOLTAGE CURRENT DC24 V 7 mA...

Page 66: ...COM1 EN GB ISSUE DATE 10 13 2017 SECTION 4 TECHNICAL DATA LD20572 Figure 18 REMOTE STOP START SIGNAL AUXILIARY EQUIPMENT PANEL ABSORPTION CHILLER HEATER CONTROL PANEL LD20573 Figure 19 SIGNAL TERMINAL...

Page 67: ...ock b Cooling water pump interlock Cooling water pump operation interlock c Normally monitoring interlock Seismoscope relay abnormal room temper ature sensor d Monitor interlock in combustion Suction...

Page 68: ...of direct fired absorption chiller heaters Upper Communication System Configuration The configuration of the upper communication system is shown in Figure 20 on page 68 LD20594a Central Monitoring Uni...

Page 69: ...ng are included Wiring work for Ethernet connection X Apply twisted pair cable Communication program for central monitoring unit X See Table 11 on page 38 and Table 12 on page 39 for the details of th...

Page 70: ...1 C 3 Temp difference of Automatic start stop control at cooling mode 5 0 C 00005 0001 1000 unit 1 unit 0 1 C 4 Automatic stop temp at heating mode thermo off temp 62 0 C 00007 0040 1000 unit 1 unit 0...

Page 71: ...unit 0 1 C 21 High temperature generator solution temp 145 0 C 00095 0001 4000 unit 1 unit 0 1 C 22 Exhaust gas temp 220 0 C 00097 0001 4000 unit 1 unit 0 1 C 23 High temperature generator pressure 70...

Page 72: ...erface COM2 Connect User Created Cable LD20597b ITEM CUSTOMER JCI REMARKS Control panel with upper communication function X Communication protocol Modbus RTU Wiring work for Modbus RTU communication X...

Page 73: ...ut Receive Data B 3 SDA Output Send Data A 4 ERA Output Data Terminal Ready A 5 SG Signal Ground 6 CSB Input Send Possible B 7 SDB Output Send Data B 8 CSA Input Send Possible A 9 ERB Output Data Term...

Page 74: ...tion resistance Signal name Slave D sub 9 pin socket Pin Shield Shell FG Shell FG Figure 23 2 WIRE N 1 CONNECTION WITH USER CREATED CABLE 4 Wire Type Cable Diagrams The following are sample cable diag...

Page 75: ...eld Shell FG Shell FG Figure 25 4 WIRE N 1 CONNECTION WITH USER CREATED CABLE The following table contains information about the communication specifications needed for the Modbus RTU See Table 13 on...

Page 76: ...3 79 93 50 85 57 80 69 83 65 73 61 63 62 62 66 65 65 63 61 58 38 36 4 80 88 40 74 52 77 64 79 59 67 58 62 66 66 70 69 67 66 63 61 41 39 5 67 82 35 73 42 69 60 77 53 62 51 55 54 54 53 52 48 47 34 33 25...

Page 77: ...ischarge pressure The delivery pressure reflects the high vacuum condition of the machine If the inside pressure is atmospheric add 1 0 kg cm 14 3 psig to the standards in table 10 Remove the compound...

Page 78: ...e and tubes When you need to reduce the quantity of the chilled hot water and cooling water temporarily use the valves to make adjustments When the flow rate change of the chilled hot water is control...

Page 79: ...he ignition sequence starts The Low Combustion lamp lights The low open ing of the capacity control valves are held for about 10 minutes After 10 minutes the capacity control valves are controlled aut...

Page 80: ...o within 3 min Yes Time up Temperature control operation Hold low combustion Ignition sequence Figure 27 COOLING START DIAGRAM Figure 28 COOLING STOP DIAGRAM Stop Operation Dilution operation starts C...

Page 81: ...d cooling water system is on a common system it is necessary to install the isolation valve on the chilled hot water and cooling water inlet pipe entering the chiller and interlock these isolation val...

Page 82: ...7 Start the chilled or hot water cooling water and residential hot water pump 8 The water box pressure does not exceed the maximum pressure for the a Chilled hot water b Cooling water c Residential h...

Page 83: ...the vacuum pump is charged with the cor rect amount of lubricant oil F Evacuate Nitrogen charge 1 Remove the plug in the purge line 2 Evacuate nitrogen gas until the HT GEN compound gauge indicates a...

Page 84: ...a Solution circulation pump b Solution spray pump c Refrigerant pump NOTES ________________________________________________________________ ___________________________________________________________...

Page 85: ...nlet temperature 12 Record the running data on the data sheets B Purge Amount check 1 Verify that the purge amount from the absorber is within acceptable range 2 Close the spindle valve to facilitate...

Page 86: ...Solution circulation pump A Standard 1 040 kg L or less Cooling Solution spray pump A Specific gravity Set base temp C Refrigerant pump A Turbidity Auto stop temp C Purge pump A Auto restart diff C He...

Page 87: ...TES m3 N h Calculation or flow meter ExhAUST GAS O2 cON cENTRATION Exhaust gas analyzer 4 0 8 0 ExhAUST GAS cO cON cENTRATION ppm Exhaust gas analyzer 100 ExhAUST GAS cO2 cON cENTRATION Exhaust gas an...

Page 88: ...panel 20 0 37 5 C Inlet pressure Pressure gauge Outlet pressure Pressure gauge 7 Pressure drop DPG or calculation 8 5 Flow rate FM or calculation 6 Absorption cycle HG pressure gauge MPa G Compound g...

Page 89: ...from Purge Line Flame Reaction Test Standard 4 0 cc min or smaller Reaction Strong Weak None Amount of Gas P cc min Purge Amount from Purge Tank Elapsed time 1 hour Consumed time for measurement m mi...

Page 90: ...JOHNSON CONTROLS 90 FORM 155 32 ICOM1 EN GB ISSUE DATE 10 13 2017 SECTION 5 COMMISSIONING THIS PAGE INTENTIONALLY LEFT BLANK...

Page 91: ...ut having to turn off the chiller heater Data can be displayed in Metric units plus keypad en try of set points to 0 1 increments Security access using passwords is provided to prevent unauthorized ch...

Page 92: ...ontinue or cancel your selection LD21476a Screen Name Buttons Each screen includes buttons for changing screens The button that is lit indicates which screen you are on They are lo cated along the bot...

Page 93: ...e control of the microcomputer panel changes to RUN status Turns off if the chiller heater stops Thermo OFF In cooling mode lights if the chilled water temperature falls to the automatic stop temperat...

Page 94: ...mp refrigerant pump purge pump chilled hot water pump cooling water pump Flickers green during operation Remains red when the pump is stopped 69WC1 69WC2 option Differential pressure switch of chilled...

Page 95: ...er Evaporator Refrigerant Temp temperature of the refrigerant in the evaporator Absorber Temp temperature of the diluted solution in the absorber Exhaust Gas Temp temperature of the exhaust gas measur...

Page 96: ...rted To move to the Trend screen press the Trend button at the upper right of the screen The History Menu section on the right side of the screen gives you access to the operation history Alarm Histor...

Page 97: ...ion of inhibitor is required When maintenance is overdue the maintenance alarm is activated with the warning Solution analysis should be done When the warning appears contact your lo cal Johnson Contr...

Page 98: ...screen and the Refrigerant Pump Overhaul section of the screen both indicate the maintenance interval and the current operation hours since the last maintenance When the required maintenance period h...

Page 99: ...ce interval has passed the maintenance alarm is activated with the warning Burner parts should be replaced When the warning appears contact your local Johnson Controls service cen ter The Burner Combu...

Page 100: ...evapo rator Cooling Water Inlet temperature of the cooling water as it enters the absorber Cooling Water Outlet temperature of the cool ing water as it leaves the condenser HG Temperature temperature...

Page 101: ...olution Pump operation status of the solution pump Refrigerant Pump operation status of the refrigerant pump Burner Fan operation status of the burner fan Operation Mode selected operation mode coolin...

Page 102: ...re gen erator HG Concentration concentration of the concentrated solution in the high temperature generator Control Valve percentage that the valve is open There are two sets of buttons on the right s...

Page 103: ...Operation Mode selected operation mode cooling or heating Combustion status of the combustion ON or OFF Operation Hours how many hours the chiller heater has been running Operation Freq how many time...

Page 104: ...hat the valve is open To move to another history screen press the desired screen button to move to the desired screen in the his tory menu Hourly Operation Failure or Alarm There are two sets of butto...

Page 105: ...ation status of the refrigerant pump Burner Fan operation status of the burner fan Combustion status of the combustion ON or OFF Operation Hours total operation hours Operation Freq how many times the...

Page 106: ...in the high temperature generator Control Valve percentage that the valve is open There are two sets of buttons on the right side of the screen The first set gives you access to information about pas...

Page 107: ...tus of the refrigerant pump Burner Fan operation status of the burner fan Combustion status of the combustion ON or OFF Operation Hours total operation hours Operation Freq how many times the chiller...

Page 108: ...in the high temperature generator Control Valve percentage that the valve is open There are two sets of buttons on the right side of the screen The first set gives you access to information about pas...

Page 109: ...ghts in the Failure section of the screen Press the BUZZER STOP button to turn off the alarm sound This can be done even before the failure is addressed Turning off the buzzer does NOT fix the problem...

Page 110: ...interlocked equipment Cooling Water Pump Interlock Cooling water pump interlock was not established during cooling water pump operation command output Check the cooling water pump interlock Chilled Ho...

Page 111: ...ANCE on Page 129 HG High Pressure HG pressure rose up abnormally High Cut HG high pressure relay or exhaust gas high temperature relay was activated High Exhaust Gas Temperature Exhaust gas temperatur...

Page 112: ...n before fixing the alarm the lit alarm button will not go out Table 31 ALARM LIST ALARM NAME CAUSE OF ALARM AND CONDITION TO RESET COUNTER MEASURES Abnormal Purge Frequency Purge frequency within a s...

Page 113: ...ration was activated The alarm is reset when solution concentration reaches 158 C HG High Concentration Prevention Control High solution concentration and load limit operation was activated The alarm...

Page 114: ...t temperatures for cooling heating and residential hot water RHW Remote Setting Diff the setting range with external 4 20 mADC signal Set Point Display the setpoint of the chilled hot wa ter leaving t...

Page 115: ...in one of these fields see Change Numeric Values on page 92 VALVE OPERATION Control Valve Mode Auto Manual indicates wheth er the control valve is being operated automatically or manually To change t...

Page 116: ...15 seconds Simultaneous indicates whether the simultaneous residential hot water supply operation with the auxilia ry heat exchanger is on or off auxiliary heat exchanger equipped model only The ON O...

Page 117: ...ween the display and set values for each item Mode Indicator lights to indicate which opera tional mode is active for the unit The available lights are a Man if the MAN light is not lit the unit is in...

Page 118: ...or longer to change between the operation display mode and the setup display mode Loader Connector Allows the connection to a PC Requires the dedicated cable that is supplied with the Smart Loader Pa...

Page 119: ...the Up per Display flashes slowly The information in the dis play alternates between the normal information and the alarm code In addition the Multi Status Display lights ripple through the left and r...

Page 120: ...e AL07 Motor Feed Back MFB input failure Burnout Incorrect wiring Check the wiring Check the MFB input valve AL10 Motor adjustment failure Burnout Incorrect wiring Power for motor is shut down Check t...

Page 121: ...Air damper opening shown as a or Fb feedback value is indicated in the lower display Lower Display Control target of air damper shown as a capacity control output to the air damper shown as a or the...

Page 122: ...as a or Fb feedback value is indicated in the lower display Lower Display The Control target of the hot water control valve shown as a the Control output to the hot water control valve shown as a or t...

Page 123: ...appears release the Mode button The information in the Lower Display changes to the control output for the hot wa ter control valve At this point the information may be changed Press the Up Down arro...

Page 124: ...4 14 Press the Purge Mode Auto button on the Setting screen See Automatic Method to Purge Non con densable Gas from the Purge Tank on page 135 Changeover to Heating Mode 1 Select the appropriate metho...

Page 125: ...and refrigerant pump then start independently The chilled hot water pump should be op erating during forced dilution to prevent freezing of the chilled hot water 6 Open the refrigerant manual blow val...

Page 126: ...9 69 9 9 LJK 7HPS HDW FKDQJHU LJK 7HPS HQHUDWRU 3LORW 3LSLQJ 0DLQ 3LSLQJ 851 5 RQWURO 0RWRU RZ 7HPS HDW FKDQJHU 5HIULJHUDQW 3XPS 6ROXWLRQ LUFXODWLRQ 3XPS 6ROXWLRQ 6SUD 3XPS RZ 7HPS HQHUDWRU UDLQ HDW...

Page 127: ...upply RHW Ref Return LG HG Ref Return Purge valves Cooling X X X X X Set to automatic purge of the purging tank Heating X X X Close V10 V11 V12 V13 V14 V15 V16 Simultaneous cooling and residential hot...

Page 128: ...JOHNSON CONTROLS 128 FORM 155 32 ICOM1 EN GB ISSUE DATE 10 13 2017 SECTION 6 OPERATION THIS PAGE INTENTIONALLY LEFT BLANK...

Page 129: ...be sure to turn OFF the main circuit breaker MCB1 and fully close the main valve of fuel gas line If not it may cause electric shock and burn Contact your local Johnson Controls Service Office for ins...

Page 130: ...be used as the refrigerant in the chiller heater PURGE PROCEDURE Air must be purged from the chiller heater to maintain its performance and prevent deterioration of its internal parts This chiller hea...

Page 131: ...51 LOCATION OF MANUAL VALVE IN PURGING SYSTEM 120 300EX H S A Purge valve from purge tank V10 B Purge valve from absorber V13 C Purge valve from absorber V11 D Purge Main Valve V14 E Purge valve from...

Page 132: ...52 LOCATION OF MANUAL VALVE IN PURGING SYSTEM 360 500EX H S A Purge valve from absorber V10 B Purge valve from absorber V11 C Purge valve from absorber V13 D Purge valve from absorber V16 E Purge mai...

Page 133: ...EX S H NG A B D C E F Figure 53 LOCATION OF MANUAL VALVE IN PURGING SYSTEM 560 1600EXW3 H S A C H Changeover Valve VL Option B Refrigerant Blow Valve V8 C Refrigerant pump D Purge valve from absorber...

Page 134: ...page 168 and check the purge line 7 If no problems are found open valve V16 the rest of the way Make sure the valve is completely open 8 Continue to purge for 2 to 3 hours 9 Close valves V13 and V16 1...

Page 135: ...on page 112 2 Press the Manual Purge OFF button 3 Press the Purge Mode Auto button 4 The purge solenoid valves automatically open and close During the automatic purge operation the vacuum pump starts...

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Page 140: ...JOHNSON CONTROLS 140 FORM 155 32 ICOM1 EN GB ISSUE DATE 10 13 2017 SECTION 7 MAINTENANCE Figure 58 PROCESS AND INSTRUMENTATION DIAGRAM COOLING ONLY 317 2215780...

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Page 142: ...ent of the refrigerant depends on the current load condition Constantly check the liquid level in the refrigerant tank while the refrigerant is refined If the refrigerant liquid level appears in the l...

Page 143: ...an be seen through the high tempera ture generator level gauges G104 white The liquid level in the absorber falls and the tem perature of the solution returning from the genera tor is drops DECRYSTALL...

Page 144: ...ut 30 minutes stop the solution pump 20 Press the Refrigerant Pump Auto button 21 Return the valve cap There is an O ring between the cap and valve When fitting the cap make sure that the O ring is se...

Page 145: ...vibration C Measurement of insulation resistance of electric devices Measure the insulation resistance of the main circuit and motors solution pump refrigerant pump mainly to check for lowering of in...

Page 146: ...absorption chiller heater 4 years S Inspection of chilled hot water box and replacement of packing Open the waterbox cover periodically check the inside paint for damage and check the inside of the tu...

Page 147: ...nce of the absorption chiller heater Accordingly recommend that the machine should be checked for slight leakage with a special vacuum and airtightness diagnostic device periodically every 2 years S E...

Page 148: ...shown for refer Refrigerant Pump Manual Stop The refrigerant pump can be stopped manually for maintenance purposes It can be stopped even while the chiller heater operates 1 Navigate to the Setting sc...

Page 149: ...nnel Box every 2 years Main Circuit Board every 30 000 hrs Relay MY 2N MY 4N Timer H3Y 2 Fuse Power Unit RWS series Magnet Switch Thermal Relay HK series Battery for main circuit board CR2032 every 3...

Page 150: ...est water quality control standards Limit the water pressure to the maximum safe working pressure for chilled hot and cooling wa ter Install a 10 20 or finer mesh strainer in the chilled hot and cooli...

Page 151: ...opping the chiller heater for more than 15 days drain the water from the absorber condenser and evaporator through the drain valve at the bottom of the waterbox CHEMICAL TREATMENT Corrosion inhibitors...

Page 152: ...3 to make red water and sets red rust of ferric dioxide Fe2 O3 Iron bacteria propagate remarkably Reddish brown Black Fe3 corrodes iron and copper tubes Reddish brown Black Environmental Factors Water...

Page 153: ...ax 1 0 Max 0 1 Residual Chlorine mgCI I Max 0 3 Max 0 3 Max 0 3 Max 0 3 Max 0 3 Free Carbonate Acid mgCO2 I Max 4 0 Max 4 0 Max 4 0 Max 4 0 Max 4 0 Stability Index 6 0 7 0 NOTES 1 The item names their...

Page 154: ...ll equipment is completely dry Nitrogen gas pressurization inside the absorption chill er heater is required when the storage period exceeds 6 months Contact your local Johnson Controls Service Center...

Page 155: ...pump for 30 minutes to one hour to clean it 5 Drain the water 6 Completely fill the water systems with clear water again 7 Store the machine DRY STORAGE METHOD The dry storage method should be used if...

Page 156: ...less than 6 months Chilled hot water system Filled with water Cooling water system Inside of shells Vacuum Storage Period more than 6 months Chilled hot water system Filled with water Cooling water sy...

Page 157: ...freezing In case there is concern of freezing apply an insulation material to the cooling water piping 2 The cooling tower is installed at the high level height of the chiller heater If not the high...

Page 158: ...ber and the condenser with clean wa ter 4 Circulate the clean water with the cooling water pump for 30 min to 1 hour 5 Drain all of the cooling water from the Absorber and Condenser 6 Fill the absorbe...

Page 159: ...low the clean water from the higher location than the chiller heater and then feed the clean water continuously and clean the tubes well 3 Fill absorber and condenser with clean water 4 Circulate it w...

Page 160: ...0 210 220 CRYSTALLIZATION AREA 6 5 6 0 5 5 5 0 4 5 4 0 4 0 4 5 5 0 5 5 6 0 6 5 7 0 200 200 210 210 220 220 230 230 240 240 250 250 260 260 270 270 280 280 290 290 300 300 310 310 320 320 330 330 340 3...

Page 161: ...1 057 U S quarts 1 U S gallon 3 785 liters 1 inch 25 4 mm 1 ton refrigeration 12 000 Btu hr 3 52 kW Absorption Liquid Chillers Duhring Diagram PTX Chart 4 4 82 2 87 8 93 3 98 9 104 4 110 0 115 6 121 1...

Page 162: ...55 50 55 69 55 87 56 05 56 23 56 40 56 58 1 620 54 93 55 12 55 31 55 49 55 68 55 86 56 05 56 23 56 41 56 59 56 76 56 94 57 11 1 630 55 47 55 66 55 85 56 03 56 22 56 40 56 58 56 76 56 94 57 12 57 29 57...

Page 163: ...52 63 52 81 52 99 53 18 53 36 53 53 53 71 1 55 50 89 51 10 51 30 51 50 51 69 51 89 52 08 52 28 52 47 52 66 52 84 53 03 53 21 53 40 53 58 53 76 53 94 54 11 54 29 1 56 51 49 51 69 51 89 52 09 52 29 52...

Page 164: ...JOHNSON CONTROLS 164 FORM 155 32 ICOM1 EN GB ISSUE DATE 10 13 2017 SECTION 7 MAINTENANCE THIS PAGE INTENTIONALLY LEFT BLANK...

Page 165: ...them Several items should be checked routinely whenever the chiller heater experiences any trouble or abnormal ity Check to see if the main fuel gas valve was closed by mistake Open the main valve Se...

Page 166: ...hibitor is worn 7 Air leaks in absorption chiller heater Table 43 REFRIGERANT OVERCOOLING RELAY ITEM CAUSE COUNTERMEASURE 1 Chilled hot water flow rate lowers or changes sharply See if the chilled hot...

Page 167: ...em occurs the absorption chiller heater performs the dilution operation automatically and then stops Go to the Control Center immediately to confirm that the dilution took place If it did not dilute t...

Page 168: ...n switch If it is low check the flow controller check the strainer for clogging Check the opening ratio of the flow control valve 3 Pressure transfer pipe of water suspension switch is clogged Contact...

Page 169: ...on Controls Service Office 4 Non condensable gas remains in machine See Purge Procedure on page 130 Check the capacity of the vacuum pump Check the purge unit for trouble Purge non condensable gas fro...

Page 170: ...l during the vacuum pump capacity check the whole of the purge line needs to be inspected See Table 42 on page 167 Table 52 VACUUM PUMP TROUBLESHOOTING ITEM CAUSE COUNTERMEASURE 1 Deterioration of vac...

Page 171: ...ratio of the flow controller valve and check the strainer for clogging Check the capacity of the cooling tower See Purge Procedure on page 130 Check the capacity of the vacuum pump Check the purge uni...

Page 172: ...terioration of vacuum pump oil Replace the vacuum pump oil 3 Wrong operation of purging line switching when the vacuum pump capacity was checked See Purge Procedure on page 130 Confirm that the valve...

Page 173: ...bnormal Failure indicator light ON 1 1 Yes Yes No No No Yes Reset operation buzzer OFF External outlet issues No Yes Dilution operation complete Stop dilution operation Yes Damper fully closed Burner...

Page 174: ...ler heater Monitor until chiller heater returns to normal operation Purge directly from the absorber Stop the machine to ensure the dilution operation takes place The dilution operation takes approxim...

Page 175: ...heat exchanger sec tion of the system If no isolation valves are in stalled it may be necessary to drain the complete system 6 If glycol was used in the water system or chemi cal additives are contain...

Page 176: ...nia USA 17349 800 861 1001 Subject to change without notice Printed in USA Copyright by Johnson Controls 2017 www johnsoncontrols com ALL RIGHTS RESERVED Form 155 32 ICOM1 EN GB 1017 Supersedes 155 32...

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